Electrolysis apparatus

Abstract

Disclosed is an electrolyzer which includes a plurality of partitions, each of which are hollowed out on either side thereof, a plurality of substrates, each of which is disposed in the hollow of a different one of said partitions and each of which is corrugated on one side thereof, with the corrugated side coated with an anodic material, a plurality of solid polymer electrolyte membranes, one side of each of which is disposed in contact with the anodic material of a different one of said substrates, and a plurality of cathode plates composed of porous cathodic material, each of which is disposed in the other hollow of a different one of the partitions and is positioned in contact with the other side of a different one of the membranes. The partitions, substrates, membranes and cathode plates are secured together in a series relationship with the corrugated side of each substrate being held in contact with one side of a membrane and each cathode plate being held in contact with the other side of a corresponding membrane. Channels are formed in the corrugated side of the substrates to convey water to the grooves formed by the corrugations, and a conduit is formed to extend through the partitions to deliver water to the channels. Other channels are formed in the substrates to receive water and electrolysis products from the grooves and to deliver the water and products to a second conduit formed in the partitions. A third conduit is formed in the partitions to receive electrolysis products at the interfaces of the membranes and cathode plates. A direct current source supplies current to the substrates and cathode plates to cause an electrolytic reaction when water is supplied to the grooves of the corrugated sides of the substrates.

What is claimed is: 
     
       1. An electrode structure for electrolysis apparatus having a solid polymer electrolyte membrane and a pair of electrodes disposed on either side of and in contact with the membrane, at least one of said electrodes including a corrugated surface portion which presents alternating ridges and grooves, with the ridges being maintained in contact with the membrane so that the portions of the membrane in contact with the ridges are deformed to conform in shape to the tops of the ridges and the grooved bottoms being spaced from the membrane to enable the flow of fluid through the grooves, said corrugated surface portion extending over a generally circular area and in a substantially flat plane. 
     
     
       2. An electrode structure as in claim 1 wherein the tops of the ridges and the bottoms of the grooves are generally rounded 
     
     
       3. An electrode structure as in claim 1 wherein the tops of the ridges are generally flat, and wherein the grooves are formed to have a generally horseshoe-shaped cross-section. 
     
     
       4. An electrode structure as in claim 1 wherein the grooves and ridges are disposed in a substantially linear parallel relationship. 
     
     
       5. An electrode structure as in claim 4 wherein the cross-sectional area of the grooves extending through the circular area near the center thereof is greater than the cross-sectional area of the grooves extending through the circular area near the edges thereof. 
     
     
       6. An electrode structure as in claim 5 wherein the cross-sectional area of each groove is proportional to its length. 
     
     
       7. An electrode structure as in claim 1 wherein the ridges and grooves are formed concentrically in said surface portion substantially about the center thereof. 
     
     
       8. An electrode structure as in claim 7 wherein the cross-sectional area of the grooves formed concentrically near the center of the circular area is less than the cross-sectional area of the grooves formed concentrically near the edge of the circular area. 
     
     
       9. An electrode structure as in claim 8 wherein the cross-sectional area of each groove is proportional to the distance of the groove from the center of the circular area. 
     
     
       10. An electrolyzer comprising a plurality of substrates, each formed with corrugations on one side thereof to present alternating ridges and grooves and each being coated on the corrugated side with anodic material, said substrates being arranged in series so that the coated sides thereof face in the same direction,   a plurality of solid polymer electrolyte membranes, one side of each of which is disposed in contact with the anodic material of a different one of said substrates,   a plurality of cathode plates composed of porous cathodic material, each disposed in a generally parallel relationship and in contact with the other side of a different one of said membranes,   means defining chambers about each cathode plate into which may flow gas products produced at the interfaces of the membranes and cathode plates,   means for securing the substrates, membranes and cathode plates in a series relationship,   means for conveying water to the grooves located on each substrate,   means for applying a D.C. current to the substrates and the cathode plates,   first means for receiving water and products produced at the interfaces of the membranes and anodic material, and   second means for receiving products produced at the interfaces of the membranes and cathode plates.   
     
     
       11. An electrolyzer as in claim 10 wherein said substrates are generally rectangular and said ridges and grooves extend from near one edge of the substrates to near the opposite edge thereof, wherein said water conveying means comprises means defining a plurality of first channels, each extending generally perpendicularly to the ridges and grooves of a corresponding substrate at one end thereof and adapted to convey water to such grooves,   wherein said first receiving means comprises means defining a plurality of second channels, each extending generally perpendicularly to the ridges and grooves of a corresponding substrate at the end thereof opposite the location of the first channels and adapted to receive water and products produced at the interfaces of the membranes and anodic material, and   wherein said second receiving means comprises a plurality of third channels defined in the chamber defining means to communicate with and receive from the chambers products produced at the interfaces of the membranes and cathode plates.   
     
     
       12. An electrolyzer as in claim 10 wherein said substrates are generally circular and said ridges and grooves extend from near one edge of the substrates to near the other edge thereof generally in a parallel relationship, wherein said water conveying means comprises means defining a plurality of first channels, each extending adjacent the terminations of the ridges and grooves of a corresponding substrate at said one edge thereof to convey water to the grooves,   wherein said first receiving means comprises means defining a plurality of second channels, each extending adjacent the terminations of the ridges and grooves of a corresponding substrate at said other edge thereof to receive water and products produced at the interfaces of the membranes and anodic material, and   wherein said second receiving means comprises a plurality of third channels defined in the chamber defining means to communicate with and receive from the chambers products produced at the interfaces of the membranes and cathode plates.   
     
     
       13. An electrolyzer as in claim 12 wherein said chamber defining means comprises a plurality of partitions, each disposed between a different substrate and cathode plate and each having a generally planar profile and a hollow formed in either side thereof, one of such hollows being adapted to receive and hold a substrate and the other of such hollows being adapted to receive and hold a cathode plate, said partitions being arranged in series to maintain the anodic material of each substrate and each cathode plate in contact with and on either side of a corresponding membrane. 
     
     
       14. An electrolyzer as in claim 13 wherein the cross-sectional areas of the longer grooves in the substrate are greater than the cross-sectional areas of the shorter grooves. 
     
     
       15. An electrolyzer as in claim 10 wherein said substrates are generally circular and said ridges and grooves are formed concentrically in the substrates, wherein said water conveying means comprises a plurality of first channel means, each formed in the coated side of a different one of said substrates to extend from near the center of the substrate generally radially outwardly through the ridges to the edge of the substrate to convey water to the corresponding grooves,   wherein said first receiving means comprises a plurality of second channel means, each formed in the coated side of a different one of said substrates to extend from near the center of the substrate generally radially outwardly through the ridges to the edge of the substrate to receive water and products from the corresponding grooves, each of said second channel means being spaced apart from the first channel means on the corresponding substrate, and   wherein said second receiving means comprises a plurality of third channel means formed in said chamber defining means to communicate with and receive products from the chambers.   
     
     
       16. An electrolyzer as in claim 15 wherein the cross-sectional area of the grooves formed concentrically near the center of a substrate is less than the cross-sectional area of the outer-most grooves of the substrate. 
     
     
       17. An electrolyzer as in claim 14 wherein said chamber defining means comprises a plurality of partitions, each formed to have a generally planar profile with a hollow in each side thereof, one of said hollows being adapted to receive and hold a substrate and the other of said hollows being adapted to receive and hold a cathode plate, said partitions being arranged in a series relationship to maintain the anodic material of each substrate and cathode plate in contact with and on either side of a corresponding membrane. 
     
     
       18. An electrolyzer as in claim 17 wherein said water conveying means further comprises first conduit means formed to extend through the partitions generally perpendicularly therewith and to communicate with and convey water to each of said first channel means, wherein said first receiving means further comprises second conduit means formed to extend through the partitions generally perpendicularly therewith and to communicate with and receive water and products from each of said second channel means, and wherein said second receiving means further comprises third conduit means formed to extend through the partitions generally perpendicularly therewith and to communicate with and receive products from each of said third channel means. 
     
     
       19. An electrolyzer as in claim 18 wherein each first and second channel means of a substrate are formed in the substrate at an angle of about 180° apart. 
     
     
       20. An electrolyzer as in claim 19 wherein said first, second and third conduit means extend through the partitions at locations between the partition hollows and the outer edge of the partitions, wherein the first and second channel means extend respectively from the first and second conduit means toward the center of the substrates, and wherein the third channel means extend from the third conduit means into the hollow of each partition in which is held the cathode plate. 
     
     
       21. An electrolyzer as in claim 17 further including a plurality of biasing means disposed in each hollow in which a cathode plate is held to force the cathode plates against the corresponding membranes.